JPH04224882A - Composite rotor disc - Google Patents

Abstract

PURPOSE:To provide a lightweight rotor disc which is excellent in corrosion resistance, etc., and can remedy the deficiency of conventional rotor discs made of iron. CONSTITUTION:A rotor disc obtained by putting together a disc body made of iron, aluminum or titanium and a ceramic friction member made by sintering a powder of alumina, silicon nitride, sialon or silicon carbide having a purity of 99% or higher and a particle size of 1mum or smaller to a sinter density of 98.5% or higher. It is very lightweight with high strength and excellent in frictional performance and abrasion resistance. It is so hard that it is difficullty marred and is excellent in corrosion resistance and durability. It also has high toughness. Therefore, it is effective in reducing the weight of an automobile disc brake mechanism.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite rotor disk, and more particularly to a composite rotor disk that is lightweight, has high strength, has excellent durability, and is effective in reducing the weight of rotor disks in automobile disc brake mechanisms and the like.

0002

2. Description of the Related Art Conventionally, rotor disks for automobiles have been mainly made of iron because of their low cost, high reliability of materials, and ease of manufacture.

[0003] Nowadays, from the perspective of global environmental conservation,
In the automobile-related field, there is also a movement towards energy conservation, and as a countermeasure to this, reducing the weight of automobiles has become a major issue. Therefore, it is desired that the weight of the rotor disk be reduced as well.

0004

[Problems to be Solved by the Invention] Conventional steel rotor disks for automobiles are heavy. ■Easy to rust. There are drawbacks such as (2), which has a large effect on the fuel efficiency, acceleration, and inertia of the automobile, and (2), which causes rust, which is a drawback to the braking force and braking mechanism, and goes against energy conservation.

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems and provide a composite rotor disk that is lightweight, has high strength, and has excellent durability.

[0006]

[Means for Solving the Problems] The composite rotor disk of the present invention is a composite rotor disk in which a ceramic friction member is adhered or bonded to a metal disk body, and the metal disk body includes: A ceramic friction member made of one metal or an alloy of two or more selected from the group consisting of iron, aluminum, and titanium,
Sintered powder made of alumina, silicon nitride, sialon, or silicon carbide with a purity of 99% or more and a particle size of 1 μm or less with a density of 98
．． It is characterized by being sintered to 5% or more.

The present invention will be explained in detail below. The metal disk body of the composite rotor disk of the present invention is made of one or more alloys selected from the group consisting of iron, aluminum, and titanium. If the thickness of such a metal disk body is too thin, the strength will be insufficient, and if it is too thick, the weight will increase, which is not preferable. Therefore, the thickness is set to about 1/2 to 1/3 of the total thickness of the rotor disk, specifically about 3 to 5 mm, particularly about 2.5 to 4 mm.

On the other hand, the ceramic friction member of the composite rotor disk of the present invention is made of alumina (Al2O3), silicon nitride (Si3 N4), sialon, or silicon carbide, which are particularly lightweight and high strength among ceramic materials.
SiC) fine ceramic powder is sintered to a density of 98.
It is manufactured by sintering to 5% or more,
The thickness is preferably about 3 to 7 mm.

These fine ceramic powders used as sintering raw materials are fine particles with a particle size of 1 μm or less, and are high-purity fine ceramic powders with a purity of 99% or more. If it has a high purity of 99% or more, the excellent properties of alumina, silicon nitride, sialon, or silicon carbide can be fully exhibited, and if it is a fine powder with a particle size of 1 μm or less, high-density sintering is possible. , is highly suitable for the present invention.

[0010] The ceramic friction member according to the present invention includes:
Such sintered raw material powder is processed, for example, by a press method or CI
It can be easily manufactured by forming it into a disk using the P (isostatic pressing) method and firing it to a sintered density (relative density) of 98.5% or more using a firing method suitable for each raw material ceramic. Here, the firing method is not particularly limited, and pressureless sintering, atmosphere sintering, HIP (hot isostatic pressing) method, etc. can be adopted.

[0011] By bonding or joining the ceramic friction member manufactured in this way and the metal disk body by brazing, diffusion bonding, etc.,
The composite rotor disk of the present invention can be easily manufactured.

0012

[Operation] The composite rotor disk of the present invention is made by integrating a metal disk body and a ceramic friction member, and has the excellent properties of both metal and ceramics. Among the constituent metals of the metal disk body, iron has excellent strength and heat resistance, but has the disadvantage of being heavy. On the other hand, aluminum and titanium are lightweight, but have problems with friction characteristics and heat resistance. On the other hand, ceramic sintered bodies are lighter than iron, have excellent corrosion resistance, high wear resistance, and high hardness. In particular, alumina, silicon nitride, sialon,
Silicon carbide is lightweight and has high strength among ceramics. In particular, a high-density sintered body with a sintered density of 98.5% or more has significantly excellent mechanical properties such as strength, hardness, wear resistance, and friction performance, and corrosion resistance.

In the composite rotor disk of the present invention, since the ceramic friction member is integrated with the metal disk body, the heat resistance and frictional properties of the friction surface are ensured by the ceramic friction member, and the ceramic friction member is lightweight. At the same time, the metal disk body ensures mechanical properties such as impact resistance and toughness that ceramics lack.

According to the composite rotor disk of the present invention, (1) it is lighter than the conventional iron rotor disk; ■Because it does not rust like conventional iron rotor disks,
No problems with the braking mechanism. ■Compared to iron rotor disks, the rotor surface has greater hardness, and the rotor will not be scratched by deposits or other debris. ■Less affected by the material on the disc pad side. ■ Excellent impact resistance, toughness, and high strength. The following effects are achieved.

[0015]

[Examples] The present invention will be explained in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to the following Examples unless it exceeds the gist thereof.

Examples 1 to 6, Comparative Example 1 Using the fine ceramic raw material powder shown in Table 1, C
Formed into a disk shape by IP and then sintered, 200mm in diameter.
Ceramic friction members having the thickness shown in Table 1 were manufactured. In addition, the molding pressure of CIP is 1500 kg/cm2,
Sintering is performed at the optimum temperature for each ceramic raw material (1600 to 18
00°C), and the relative density by sintering was 98.5% or more. All ceramic raw material powders used have a purity of 99.
% or more, and the particle size is 1 μm or less.

Separately, a diameter 20 mm made of the metal shown in Table 1
A metal disk body having a thickness of 0 mm as shown in Table 1 was manufactured, and the friction member described above was bonded and integrated to this disk body by brazing or diffusion bonding. The obtained rotor disk was subjected to a performance test and compared with a conventional iron rotor disk (Comparative Example 1). The results are shown in Table 1.

[0018]

[Table 1]

[0019] From Table 1, the composite rotor disk of the present invention has a friction coefficient that is almost as good as that of the conventional iron rotor disk, has good wear resistance, and has high hardness. It is clear that the rotor disk is significantly superior to iron rotor disks in terms of scratch resistance and durability, and is also extremely lightweight, with a weight reduction of 30 to 40% compared to conventional iron rotor disks.

[0020]

Effects of the Invention As detailed above, the composite rotor disk of the present invention has excellent friction performance, wear resistance, mechanical strength, corrosion resistance, durability, heat resistance, and impact resistance, and has high hardness and A highly tough yet extremely lightweight rotor disk is provided. The composite rotor disk of the present invention can be used in disc brake mechanisms for automobiles, etc. to reduce the weight thereof, and is extremely useful industrially.

Claims (1)

[Claims] 1. A composite rotor disk comprising a metal disk body and a ceramic friction member adhered or bonded, wherein the metal disk body is made of one type selected from the group consisting of iron, aluminum, and titanium. The ceramic friction member is made of alumina, silicon nitride, sialon, or silicon carbide powder with a purity of 99% or more and a particle size of 1 μm or less and a sintered density of 98.5% or more. A composite rotor disk characterized by being sintered into.